The U.S. Department of Energy Initiative on Battery Manufacturing

Transcription

1 The U.S. Department of Energy Initiative on Battery Manufacturing Patrick B. Davis Program Manager, Vehicle Technologies, DOE Meeting Global Challenges: US-German Innovation Policy 1 November 2010 The National Press Club th Street, NW Washington, DC

2 DOE Vehicle Technologies Program Goals Decrease petroleum dependency Reduce greenhouse gases Develop more energy efficient and environmentally friendly highway transportation technologies that enable America to use less petroleum Develop technologies that provide Americans with greater freedom of mobility and energy security, with lower costs and lower impacts on the environment Program Name or Ancillary Text eere.energy.gov

3 We are Highly Dependent on Oil U.S. transportation fuel share (2008) Transportation is responsible for 2/3 of our petroleum usage On-Road vehicles responsible for ~80% of transportation petroleum usage U.S. Vehicle Market > 240 Million vehicles on the road Approximately 11M new cars & light trucks for 2010; average is 15.7 M/yr Hybrid vehicles now <3% of sales

4 New Oil Reserves are Harder to Find Global discovery of new oil fields peaked in U.S. oil production peaked in World oil production has hardly grown at all since Source: Jeff Rubin, Why the World is About to Get a Whole Lot Smaller World Oil Oil Production 2005: mbpd 2006: mbpd 2007: mbpd 2008: mbpd 2009: mbpd The Cost of Oil is More than Monetary Program Name or Ancillary Text eere.energy.gov

5 Analysis Informs Strategy Projected Vehicle Technology for GHG Emissions and Petroleum Consumption by Vehicle Technology Vehicle GHG emissions fall into 3 major groups: Conventional Electric-drive Combination electric-drive & biofuel Petroleum consumption loosely mirrors GHG emissions Ref SI Adv SI Adv CI SI HEV SI PHEV10 SI PHEV40 CI HEV CI PHEV10 CI PHEV40 FC HEV EV E85 HEV E85 PHEV10 E85 PHEV40 Lifecycle GHG emissions (g CO2 eq / mi) GHG Emissions (g CO2-eq / mi) Petroleum Consumption (gal gas-eq / mi) Reference vehicle GHG emissions: 430 g CO2eq /mi 50% reduction fromreference vehicle GHG emissions: 215 g CO2eq /mi Petroleum Consumption (gal gasoline-eq / mi)

6 DOE Electric Drive Activities Unprecedented Investment in Advanced Vehicle Technologies A 50% increase in Vehicle Technologies Program budget in the last 2 years 1/2 of our over $311M budget directly on vehicle electrification initiatives $25B Advanced Technology Vehicles Mfg Loan Program, The launch of ARPA-e The Recovery Act's greater than $2.8B in grants for vehicle technology & demos Other DOE Vehicle Activities VT ARRA Activities $2.8 B ATVM Loan Program $25.0 B Other DOE Office of Science ARPA-E Office of Electricity

7 Open Questions About Electric Drive What s Different This Time Grid Capacity Battery Cost Charging Infrastructure

8 What s Different This Time Answer: Urgency to Solve Energy and Environmental Challenges Battery Technology

9 Vehicle Electrification: Grid Impacts In the U.S., current grid capacity could supply about 70% of our vehicles without adding capacity, but assumes: vehicle would charge only during off-peak perfect distribution of electricity No localized affects such as overburdening neighborhood transformers EVs and PHEVs will not cause a grid meltdown, but we clearly need to work fast as vehicles are rolled out to reduce impacts Smart Charging will be key to lowering cost and minimizing impacts Time of day pricing also important

10 Buildout of Charging Infrastructure Key today: Home Charging Need to get the cost and installation process right. Currently a significant barrier Public Charging Expensive if not well utilized Expansive to fully cover full driving patterns Ideally need market pull to determine public infrastructure buildout PHEVs are key to help initiate market pull for public infrastructure Public Workplace Retail Residential

11 Hybrid-Electric Systems Petroleum Displacement via Fuel Substitution & Improved Efficiency Administration Goal:1 Million PHEVs by 2015 Types of Vehicles and Benefits HEV Toyota Prius 50 MPG PHEV Battery Cost per kw h $1,000 - $1,200 System Cost 2008 APEEM Cost per kw $22 PHEV EV Chevy Volt >100 MPGe Nissan Leaf All Electric $700 - $950 Goal = $500 Goal = $300 $19 Goal = $ Goal = $12 Cost reduction will occur primarily through improvements in in chemistry not manufacturing technology

12 Recovery Act : $2.8 Billion Advanced Vehicle Technology Projects $1.5 Billion in funding to accelerate the manufacturing and deployment of the next generation of U.S. batteries $500 Million in funding for electric-drive components manufacturing SuperTruck and Advanced Combustion R&D $104.4 Million Solicitation: Heavy-duty trucks are emphasized because they rapidly adopt new technologies and account for 20% of the fuel consumed in the United States. $400 Million in funding for transportation electrification Clean Cities: $300M for Petroleum Displacement through Alternative Fuel Vehicles and Expanded Alternative Fuel Infrastructure

13 Recovery Act Opportunity Energy Storage Announcement Recovery Act Approach FOA strategy Establish a complete value chain for lithium battery manufacturing: from material supply, to cell production, to pack assembly Seed money to get started 500,000 PEVs/yr = <5% of market Sized to support market growth Expect industry to grow Electric Drive Component Integrated Supply Chain Material Suppliers Cell Manufacturer Battery Assembler End User

14 Battery Market Values Lithium battery market worldwide currently: $8 billion* (2009), largely consumer electronics applications Hybrid vehicle battery market worldwide currently: largely nickel metal hydride ~500,000 ~$3,000 each ==> ~$1.5 billion Market estimates for automotive lithium batteries (worldwide) 2015: ~800,000 ~$10,000 each ==> ~$8 billion 2020: ~6,000,000 ~$5,000 each ==> ~$30 billion * H. Takeshita, 26th International Battery Seminar, Ft Lauderdale, FL, March 2009 ** Roland Berger, 2010; Pike Research, 2010

15 Recovery Act Battery Events President Obama at Compact Power Secretary Chu at General Motors President Obama at Celgard Vice-President Biden at Dow Kokam Governor Granholm at Toda America

16 Battery Manufacturing Facilities Company Location Total Investment Cell Manu. Pack Assembly Description Holland, MI Lebanon, OR $600 M Li-Ion: Nickel Metal Cobalt Romulus & Brownstown, MI St. Clair & Holland, MI $500 M $390 M Li-Ion: Iron Phosphate Li-Ion: Mixed Manganese Brownstown, MI $236 M Jacksonville, FL $191 M Li-Ion: Nickel Metal Cobalt Midland, MI $490 M Manganese Spinel Bristol, TN & Columbus, GA Lyon Station, PA $70 M Spiral Wound AGM and Flat Plate Batteries $98 M Advanced VRLA and the Ultra Batteries Indianapolis, IN $180 M Li-Ion: Nickel Metal Cobalt

17 Battery Materials, Production and Recycling Company Location Funding Material Description Elyria, OH $50 M Cathode Goose Creek, SC $70 M Cathode Sanborn, NY $23 M Anode Batesville, AR $25 M Anode Zachary, LA $41 M Electrolyte Buffalo, NY & Metropolis, IL $55 M Electrolyte Charlotte, NC & Aiken, SC $101 M Separator Silverpeak, NV & Kings Mtn., NC $60 M Lithium Albany, OR $28 M Carbon Holland, MI $10 M Cell Casing Lancaster, OH $19 M Recycling Lebanon, OR $26 M Separator Production of nickel-cobalt-metal cathode material for Li-ion batteries Production of nickel-cobalt-metal cathode material for Li-ion batteries Production of carbon powder anode material for Li-ion batteries Production of high-temp anode material for Li-ion batteries Production of electrolytes for Li-ion batteries Production of electrolyte salt for Li-ion batteries Production of polymer separator material for lithium-ion batteries Production of battery-grade lithium carbonate and lithium hydroxide Production of high-energy density nano-carbon for ultracapacitors Manufacturing of precision aluminum casings for cylindrical cells Hydrothermal recycling of Li-ion batteries Production of battery separators for HEVs and EVs

18 Electric Drive Vehicle Components Company Location Funding (DOE / Total) Description Anderson, IN $60 M / $120 M Motor and Inverter Manufacturing Kokomo, IN Indianapolis, IN $89 M / $179 M $63 M / $126 M Inverter, Converter, and Controller Manufacturing Production of Commercial Truck Hybrid Systems Sterling Heights, MI $63 M / $125 M Production of HEV and PHEV Transaxles Simpsonville, SC $15 M / $32 M DC Bus Capacitor Manufacturing Frederick, CO $45 M / $90 M Electric Propulsion System Manufacturing Barre, VT $9 M / $18 M DC Bus Capacitor Manufacturing Youngwood, PA $6 M / $9 M Electric Drive Semiconductor Manufacturing Holly, MI; Muncie, IN $40 M / $87 M Inverter, Converter, Controller, Charger, and Electric Drive System Manufacturing White Marsh, MD; Wixom, MI $105 M / $246 M Electric Drive Motor and Unit Manufacturing

19 American Reinvestment and Recovery Act Transportation Electrification Transportation Electrification Demonstration Projects 8 Grants representing the largest ever coordinated deployment of electric-drive vehicles and charging infrastructure in the U.S. Deployment of 7,000 electric-drive vehicles, including light-duty, mediumduty, and heavy-duty passenger and commercial vehicles in a variety of climatic and operating environments Installation of over 20,000 Level 2 (240VAC) vehicle charging sites at residential, commercial, and public locations and 350 Level 3 (500VDC) Fast Chargers Collection of detailed operational data from vehicles and charging infrastructure, to evaluate and analyze vehicle usage, charging patterns, and potential grid impacts in preparation for broader, long-term deployment of vehicles and infrastructure 10 Grants to establish comprehensive educational and outreach programs focused on electric-drive vehicles Funding of the first programs to educate first responders and emergency personnel in how to deal with accidents involving EVs and PHEVs 19

20 American Reinvestment and Recovery Act Smart Grid Investment Grants Smart Grid Systems and Equipment Numbers of Units (self-reported estimates) Improvements Smart Meters 18,179,912 13% of the 142 million customers in the U.S. Load Control Devices 176,814 Enables peak demand reductions PHEVs / Charging Stations (100 projects: $3.4B Federal; $4.7B non-federal) 12 / 100 Accelerates market entry Smart Transformers 205,983 Enables preventative maintenance Automated Substations 671 5% of 12,466 transmission and distribution substations in the U.S. 2 0

21 Contact Information Patrick Davis, Program Manager

22 Building the Electric Vehicle Industry Panel Moderator: Kevin Hurst, Ph.D. Office of Science and Technology Policy Executive Office of the President November 1, 2010

23 Presidential Priorities Protect our nation from the serious economic and strategic risks associated with our reliance on foreign oil and the destabilizing effects of a changing climate. Advance energy and climate security via promoting economic recovery efforts, accelerating job creation, and driving clean energy manufacturing. Commitment to comprehensive energy-climate policies that will: o reduce dependence on foreign oil; o improve air & water quality; o cut back the carbon pollution that is changing the climate; o create new American jobs around the clean, domestic energy sources that will get all this done.

24 The American Innovation Strategy Invest in the building blocks of innovation restore leadership in fundamental research boost STEM education strengthen physical infrastructure develop an advanced IT ecosystem Promote competitive markets to spur innovation support capital markets that fund innovation encourage innovation based entrepreneurship boost public sector & community innovation promote American exports Catalyze breakthroughs for national priorities unleash a clean energy revolution support advanced vehicle technology drive breakthroughs in health IT address other grand challenges of the 21st century

25 The Administration has made an unprecedented investment in advanced vehicle technologies Recovery Act -$2.8B in grants for EV technology and demonstrations. -$7500 per-vehicle tax credit for EVs and PHEVs. -$4.5B for Smart Grid infrastructure. $25B for the Advanced Technology Vehicles Manufacturing Loan Program. Funding for the DOE Vehicle Technologies R&D Program increased by 50% from FY2008 to FY2010. DOE s Vehicle Technologies R&D ($311M in FY 2010) is focused heavily on vehicle electrification initiatives. ARPA-E: Batteries for Electrical Energy Storage in Transportation New CAFE standards

26 Next-Generation EV Research DOE Vehicle Technologies Program Basic research at DOE Office of Science, NSF, DOD ARPA-E Innovation Hub on Energy Storage R&D (proposed)

27 Harnessing private innovation: prizes and challenges Prizes & challenges harness the ingenuity that lurks in individuals, schools, firms all across society. Sponsors/organizers set an ambitious goal without prescribing the best means to achieve it, and pay only for results. The Administration s new challenge.gov website provides 1 stop shopping for innovators looking for opportunities. The recent Progressive Insurance / DOE Automotive X Prize illustrates the leverage in this approach. - $10M in prizes for super fuel efficient passenger vehicles (over 100 miles per gallon of gasoline equivalent) called forth $100M+ in investments in innovation by competitors. -Winning designs achieved up to 200 MPGe. Office of Science & Technology Policy Executive Office of the President

28 Policy questions 1. How can US-German and US-EU collaboration help enable the technical and market success of EVs? 2. How important is an energy storage revolution (at the device-level or system-level) to the growth of the EV industry? 3. Which government policy tools will be most important to building the EV industry over the next five years? 4. What should be the top priorities for electric utilities and State PUCs to prepare for wide-scale deployment of EVs? 5. Is government involvement needed to accelerate technical standards for EVs and EV infrastructure?